Sr. Systems Reliability Engineer

We are seeking a Senior Systems Reliability Engineer to lead Reliability & Maintainability (R&M) activities across the product lifecycle. This role focuses on R&M architecture, data-driven analysis, comprehensive documentation, and test planning for reliability verification. You will engage directly with customer counterparts on R&M reviews and milestone events, including Reliability Scoring Conferences, Corrective Action Boards, and Milestone B/C Design Reviews. 

Key Responsibilities: 

Reliability & Maintainability Architecture 

• Develop and maintain the R&M Program Plan and reliability architecture documentation, including the RAM-C (Reliability, Availability, Maintainability-Cost) Rationale Report 

• Lead Failure Modes, Effects, and Criticality Analysis (FMEA/FMECA), Fault Tree Analysis (FTA), and Reliability Block Diagram (RBD) development across system architecture 

• Develop R&M allocations and apportion reliability and maintainability requirements to lower-level items; support R&M requirements analysis and trade studies 

• Draft Reliability Predictions (per MIL-HDBK-217 and related methods) and Maintainability Analyses; maintain traceability between R&M requirements, predictions, and demonstrated performance 

• Lead Reliability-Centered Maintenance (RCM) and Level of Repair Analysis (LORA); support Testability and Built-In Test (BIT) analysis 

Data, Documentation & Test Planning 

• Establish and own the Failure Reporting, Analysis, and Corrective Action System (FRACAS); maintain closed-loop failure data collection and trending from design through test, production, and sustainment 

• Develop Failure Definitions and Scoring Criteria (FDSC) and reliability test plans tied to program milestones 

• Lead reliability growth planning and execution of reliability growth and demonstration testing, including Environmental Stress Screening (ESS) and HALT/HASS where applicable 

• Support Qualification Test Plan development, all-up-round testing, and flight and live-fire test reliability assessments 

• Develop technical documentation including R&M standards, specifications, procedures, and user guides 

• Review ground test, flight test, and live-fire test data to confirm R&M requirements compliance 

Customer Engagement & Reviews 

• Serve as primary point of contact with customers on R&M matters 

• Present R&M analyses, RAM-C Rationale Report updates, and risk posture at Milestone Reviews (A/B/C) and design reviews (PDR, CDR, TRR, PRR) 

• Lead Reliability Scoring Conferences and Corrective Action Boards (CAB) with customer participation 

• Coordinate responses to customer R&M data item deliverables and support In-Service Reviews 

Risk Management & Process Improvement 

• Lead Root Cause and Corrective Action (RCCA) investigations for failures identified through FRACAS 

• Host corrective action reviews and ensure lessons learned are implemented across the program 

• Coordinate R&M risk mitigation with Manufacturing Engineering, Logistics, Quality, and System Safety, including DMSMS/obsolescence and shelf-life and aging surveillance considerations 

• Apply digital engineering and AI-enabled tools (predictive maintenance, digital twins, automated FRACAS analytics) to R&M processes 

• Ensure compliance with MIL-STD-785, MIL-HDBK-217, GEIA-STD-0009, and other applicable R&M standards 

Basic Qualifications:  

• 7+ years as a Reliability Engineer, R&M Engineer, or equivalent reliability-critical engineering role 

• Bachelor's degree in Mechanical, Aerospace, Systems, or Electrical Engineering, or Physics 

• Expertise with MIL-STD-785, MIL-HDBK-217, and related R&M standards 

• Experience owning FRACAS, including failure tracking, root cause analysis, and corrective action closure 

• Proven experience developing and executing reliability test plans, including growth testing, demonstration testing, and Environmental Stress Screening 

• Experience engaging with customers on R&M reviews and milestone/design reviews (PDR, CDR, Milestone B/C) 

• Strong system architecture knowledge and R&M requirements decomposition and allocation 

• Extensive FMEA/FMECA, FTA, and RBD experience 

• Failure investigation with proven corrective action implementation 

• Technical writing for R&M program plans, rationale reports, procedures, and documentation 

• Design review experience (PDR, CDR, MRR) with strong presentation skills 

• Data collection, analysis, and trending for R&M metrics 

• U.S. Citizenship 

Preferred Qualifications:  

• Master's degree in engineering or related field 

• 10+ years progressive R&M experience 

• ASQ Certified Reliability Engineer (CRE) or equivalent certification 

• DoD or Navy R&M programs experience, aligned with SECNAV Reliability and Maintainability Engineering guidance 

• Quantitative reliability growth modeling (e.g., Crow-AMSAA) and Weibull analysis 

• Maintainability, Testability/BIT, LORA, and RCM experience 

• Missile, hypersonic, or munitions systems experience, including all-up-round reliability, environmental stress screening, and shelf-life/stockpile surveillance programs 

• Digital engineering and AI-enabled R&M tools (predictive maintenance, digital twins, automated FRACAS analytics) 

• Active U.S. Security Clearance or ability to obtain 

Level IV - $148k - $180k 
Level V - $180k - $219k